Filled polypropylene compositions and related automotive components

ABSTRACT

The present disclosure provides a filled composition made from and/or containing (A) a first polymer composition made from and/or containing (i) a heterophasic polypropylene copolymer and (ii) a polypropylene blend, and (B) a biofiller composition made from and/or containing a cellulose-based biofiller. The filled composition can additionally be made with and/or contain an elastomeric ethylene copolymer composition. Optionally, the filled composition can further be made with and/or contains a grafted polyolefin composition. The filled composition is useful in making automotive components.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority and benefit of U.S. ProvisionalPatent Application No. 61/864,187, filed on Aug. 9, 2013, the content ofwhich is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

In general, the present disclosure relates to the field of chemistry.More specifically, the present disclosure relates to polypropylenecompositions. In particular, the polypropylene compositions are filledand useful in automotive components.

BACKGROUND OF THE INVENTION

Some automotive components are made from polypropylene-basedcompositions. Those automotive components include spare-wheelcompartment covers, underbody panels, seat backrests, engine andtransmission covers, rear panel shelves, and door trim panels.

Fillers such as talc are used in those compositions to provide a widerange of physical properties. As an alternative to talc, biofillers suchas wood, flax, wheat straw, coconut, kenaf, and hemp have beencompounded with polymers.

BRIEF SUMMARY OF THE INVENTION

In some embodiments, the present disclosure provides a filledcomposition made from and/or containing (A) a first polymer compositionmade from and/or containing (i) a heterophasic polypropylene copolymerand (ii) a polypropylene blend, and (B) a biofiller composition madefrom and/or containing a cellulose-based biofiller. In some embodiments,the filled composition is additionally made with and/or contains anelastomeric ethylene copolymer composition can be made from and/orcontains an elastomeric ethylene copolymer. In other embodiments, thefilled composition additionally is made with and/or contains a graftedpolyolefin composition. The filled composition is useful in makingautomotive components.

In further embodiments, the present disclosure provides a filledcomposition made from and/or containing (A) from about 50 to about 95weight percent of a first polymer composition, relative to the totalweight of the filled composition, made from and/or containing (i) aheterophasic polypropylene copolymer and (ii) a polypropylene blend, and(B) from about 5 to about 50 weight percent a biofiller composition madefrom and/or containing of a cellulose-based biofiller, relative to thetotal weight of the filled composition.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter.However, this invention may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As such, it will be apparent tothose skilled in the art that the embodiments may incorporate changesand modifications without departing from the general scope of thisinvention. It is intended to include all such modifications andalterations in so far as they come within the scope of the appendedclaims or the equivalents thereof.

As used in this specification and the claims, the singular forms “a,”“an,” and “the” include plural referents unless the context dictatesotherwise.

As used in this specification and the claims, the terms “comprising,”“containing,” or “including” mean that at least the named compound,element, material, particle, or method step, etc., is present in thecomposition, the article, or the method, but does not exclude thepresence of other compounds, elements, materials, particles, or methodsteps, etc., even if the other such compounds, elements, materials,particles, or method steps, etc., have the same function as that whichis named, unless expressly excluded in the claims. It is also to beunderstood that the mention of one or more method steps does notpreclude the presence of additional method steps before or after thecombined recited steps or intervening method steps between those stepsexpressly identified.

Moreover, it is also to be understood that the lettering of processsteps or ingredients is a convenient means for identifying discreteactivities or ingredients and the recited lettering can be arranged inany sequence, unless expressly indicated.

For the purpose of the present description and of the claims whichfollow, except where otherwise indicated, all numbers expressingamounts, quantities, percentages, and so forth, are to be understood asbeing modified in all instances by the term “about”. Also, all rangesinclude any combination of the maximum and minimum points disclosed andinclude any intermediate ranges therein, which may or may not bespecifically enumerated herein.

Definitions

In the present description, the term “additives composition” refers to acomposition made from and/or containing at least one additive.

In the present description, the term “α-olefin” or “alpha-olefin” meansan olefin of formula CH₂═CH—R, wherein R is a linear or branched alkylcontaining from 1 to 10 carbon atoms. The α-olefin can be selected, forexample, from: propylene, 1-butene, 1-pentene, 1-hexene, 1-octene,1-dodecene and the like.

In the present description, the term “biofiller composition” refers to acomposition made from and/or containing at least one cellulose-basedbiofiller.

In the present description, the term “elastomer” refers to polymercompounds having rubber-like properties and crystallinity in the rangeof from about 0 percent to about 20 percent. The polymer can havecrystallinity in the range of from about 0 percent to about 5 percent.

In the present description, the term “elastomeric ethylene copolymercomposition” refers to a composition made from and/or containing atleast one elastomeric ethylene copolymer.

In the present description, the term “grafted polyolefin” refers to apolyolefin grafted with an unsaturated monomer. The unsaturated monomercan be an unsaturated polar monomer. The unsaturated monomer can containone or more oxygen atoms.

In the present description, the term “grafted polyolefin composition”refers to a composition made from and/or containing at least one graftedpolyolefin.

In the present description, the term “heterophasic polypropylenecopolymer” refers to copolymer prepared by the copolymerization ofethylene and propylene into a polypropylene matrix. The basepolypropylene may be a homopolymer or a copolymer.

In the present description, the term “homopolymer” and similar termsmean a polymer consisting solely or essentially all of units derivedfrom a single kind of monomer, e.g., ethylene homopolymer is a polymercomprising solely or essentially all of units derived from ethylene,propylene homopolymer is a polymer comprising solely or essentially allof units derived from propylene, and the like.

In the present description, the term “interpolymer” means a polymerprepared by the polymerization of at least two types of monomers orcomonomers. It includes, but is not limited to, copolymers (which canrefer to polymers prepared from two different types of monomers orcomonomers, although it can be used interchangeably with “interpolymer”to refer to polymers made from three or more different types of monomersor comonomers), terpolymers (which can refer to polymers prepared fromthree different types of monomers or comonomers), tetrapolymers (whichcan refer to polymers prepared from four different types of monomers orcomonomers), and the like.

In the present description, the terms “monomer” and “comonomer” are usedinterchangeably. The terms mean any compound with a polymerizable moietythat is added to a reactor in order to produce a polymer. In thoseinstances in which a polymer is described as comprising one or moremonomers, e.g., a polymer comprising propylene and ethylene, thepolymer, of course, comprises units derived from the monomers, e.g.,—CH₂—CH₂—, and not the monomer itself, e.g., CH₂═CH₂.

In the present description, the term “polymer” means a macromolecularcompound prepared by polymerizing monomers of the same or differenttype. The term “polymer” includes homopolymers, copolymers, terpolymers,interpolymers, and so on.

In the present description, the term “polymer composition” refers to acomposition made from and/or containing at least one polymer.

In the present description, the term “polyolefin” is used herein broadlyto include polymers such as polyethylene, ethylene-alpha olefincopolymers (EAO), polypropylene, polybutene, and ethylene copolymershaving at least about 50 percent by weight of ethylene polymerized witha lesser amount of a comonomer such as vinyl acetate, and otherpolymeric resins within the “olefin” family classification.

Polyolefins may be made by a variety of processes including batch andcontinuous processes using single, staged or sequential reactors,slurry, solution, and fluidized bed processes and one or more catalystsincluding for example, heterogeneous and homogeneous systems andZiegler, Phillips, metallocene, single-site, and constrained geometrycatalysts to produce polymers having different combinations ofproperties. Such polymers may be highly branched or substantially linearand the branching, dispersity, and average molecular weight may varydepending upon the parameters and processes chosen for their manufacturein accordance with the teachings of the polymer arts.

In the present description, the term “room temperature” refers to atemperature around 25 degrees Celsius.

In the present description, the term “thermoplastic polymer” means apolymer that softens when exposed to heat and returns to its originalcondition when cooled to room temperature.

In the present description, the terms “Ziegler-Natta-catalyzed polymer”and “Z—N-catalyzed polymer” mean any polymer that is made in thepresence of a Ziegler-Natta catalyst.

Testing

ASTM D 785 is entitled “Standard Test Method for Rockwell Hardness ofPlastics and Electrical Insulating Materials.” The term “ASTM D 785” asused herein refers to the test method covers two procedures for testingthe indention hardness of plastics and related plastic electricalinsulating materials by means of the Rockwell hardness tester. ARockwell hardness number is a number derived from the net increase indepth impression as the load on an indenter is increased from a fixedminor load to a major load and then returned to a minor load (ProcedureA). A Rockwell alpha (a) hardness number represents the maximum possibleremaining travel of a short-stroke machine from the net depth ofimpression, as the load on the indenter is increased from a fixed minorload to a major load (Procedure B). Indenters are round steel balls ofspecific diameters. Rockwell hardness numbers are always quoted with ascale symbol representing the indenter size, load, and dial scale used.Procedure A yields the indentation of the specimen remaining 15 s aftera given major load is released to a standard 10-kg minor load. ProcedureB yields the indentation of the indenter into the specimen after a 15-sapplication of the major load while the load is still applied. This testmethod was approved in 2008, the contents of which are incorporatedherein by reference in its entirety. For the referenced ASTM standards,visit the ASTM website, www.astm.org, or contact ASTM Customer Serviceat service@astm.org.

ASTM D 1238 is entitled “Test Method for Melt Flow Rates ofThermoplastics by Extrusion Plastometer.” The term “ASTM D 1238” as usedherein refers to the standard test method for determining melt flowrates of thermoplastics by extrusion plastometer. In general, this testmethod covers the determination of the rate of extrusion of moltenthermoplastic resins using an extrusion plastometer. After a specifiedpreheating time, resin is extruded through a die with a specified lengthand orifice diameter under prescribed conditions of temperature, load,and piston position in the barrel. This test method was approved on Feb.1, 2012 and published March 2012, the contents of which are incorporatedherein by reference in its entirety. For the referenced ASTM standards,visit the ASTM website, www.astm.org, or contact ASTM Customer Serviceat service@astm.org.

Throughout the present description and claims, all the standard meltindex values are measured according to ASTM D 1238, using a piston loadof 2.16 kg and at a temperature of 190 degrees Celsius. The High LoadMelt Index (or HLMI) values are also measured according to ASTM D 1238,but using a piston load of 21.6 kg and at a temperature of 190 degreesCelsius.

ISO 75 is entitled “Determination of Temperature of Deflection underLoad.” The term “ISO 75” as used herein refers to the test methods forthe determination of the temperature of deflection under load (flexuralstress under three-point loading) of plastics. Different types of testspecimen and different constant loads are defined to suit differenttypes of material. ISO 75-2 gives specific requirements for plastics(including filled plastics and fibre-reinforced plastics in which thefiber length, prior to processing, is up to 7.5 mm) and ebonite, whileISO 75-3 gives specific requirements for high-strength thermosettinglaminates and long-fiber-reinforced plastics in which the fiber lengthis greater than 7.5 mm. The methods specified are for assessing therelative behavior of different types of material at elevated temperatureunder load at a specified rate of temperature increase. The resultsobtained do not necessarily represent maximum applicable temperaturesbecause in practice essential factors, such as time, loading conditionsand nominal surface stress, can differ from the test conditions. Truecomparability of data can be achieved for materials having the sameroom-temperature flexural modulus.

ISO 178 is entitled “Plastics—Determination of Flexural Properties.” Theterm “ISO 178” as used herein refers to the standard test method fortesting the flexural properties of a material. In particular, theflexural test measures the force required to bend a beam under threepoint loading conditions. The data can be used to select materials forparts that will support loads without flexing. Flexural modulus is usedas an indication of a material's stiffness when flexed. Since thephysical properties of many materials can vary depending on ambienttemperature, it is sometimes appropriate to test materials attemperatures that simulate the intended end use environment. Thespecimen can lie on a support span and the load is applied to the centerby the loading nose producing three point bending at a specified rate.The parameters for this test are the support span, the speed of theloading, and the maximum deflection for the test. These parameters arebased on the test specimen thickness and are defined differently by ASTMand ISO standards. For ASTM D 790, the test is stopped when the specimenreaches 5% deflection or the specimen breaks before 5%. For ISO 178, thetest is stopped when the specimen breaks. Of the specimen does notbreak, the test is continued as far as possible and the stress at 3.5%(conventional deflection) is reported. A variety of specimen shapes canbe used for this test, including the specimen size for ASTM of 3.2mm×12.7 mm×125 mm (0.125″×0.5″×5.0″) and for ISO of 10 mm×4 mm×80 mm. Byusing the flexural text, the following data may be obtained: flexuralstress at yield, flexural strain at yield, flexural stress at break,flexural strain at break, flexural stress at 3.5% (ISO) or 5.0% (ASTM)deflection, and flexural modulus.

ISO 180 is entitled “Determination of Izod Impact Strength.” The term“ISO 180” as used herein refers to the test method for determining theIzod impact strength of plastics under defined conditions. A number ofdifferent types of specimen and test configurations are defined.Different test parameters are specified according to the type ofmaterial, the type of test specimen and the type of notch.

ISO 527 is entitled “Plastics—Determination of Tensile Properties.” Theterm “ISO 527” as used herein refers to the test methods for determiningthe tensile properties of plastics and plastic composites under definedconditions. Several different types of test specimen are defined to suitdifferent types of material. The methods are used to investigate thetensile behavior of the test specimens and for determining the tensilestrength, tensile modulus and other aspects of the tensile stress/strainrelationship under the conditions defined.

ISO 1183 is entitled “Methods for Determining the Density ofNon-Cellular Plastics.” The term “ISO 1183” as used herein refers to thetest method for the determination of the density of non-cellular moldedor extruded plastics in void-free form. In this gradient column method,density gradient columns are columns containing a mixture of twoliquids, the density in the column increasing uniformly from top tobottom.

Incorporated Unsaturated Monomer (Weight Percent): The amount of theunsaturated monomer incorporated into the grafted polyolefin can bemeasured by wet chemical methods (titration, etc.) or Fourier transforminfrared spectroscopy (FTIR).

“Molecular Weight Distribution (Mw/Mn)” is measured by gel permeationchromatography. MWD and the ratio M_(w)/M_(n), are determined using aWaters 150-C ALC/Gel Permeation Chromatography (GPC) system equippedwith a TSK column set (type GMHXL-HT) working at 135 degrees Celsiuswith 1,2-dichlorobenzene as solvent (ODCB) (stabilized with 0.1 vol. of2,6-di-t-butyl p-cresole (BHT)) at flow rate of 1 ml/min. The sample isdissolved in ODCB by stirring continuously at a temperature of 140degrees Celsius for 1 hour. The solution is filtered through a 0.45 μmTeflon membrane. The filtrate (concentration 0.08-1.2 g/l injectionvolume 300 μl) is subjected to GPC. Monodisperse fractions ofpolystyrene (provided by Polymer Laboratories) are used as standard.

Xylene Solubles for Polymers (percent by weight): 2.5 g of polymer aredissolved in 250 ml of xylene, at 135 degrees Celsius, under agitation.After 20 minutes, the solution is cooled to 0 degrees Celsius understirring, and then it is allowed to settle for 30 minutes. Theprecipitate is filtered with filter paper; the solution is evaporatedunder a nitrogen current, and the residue dried under vacuum at 140degrees Celsius until constant weight. The weight percentage of polymersoluble in xylene at 0 degrees Celsius is then calculated. The percentby weight of polymer insoluble in xylene at room temperature isconsidered the isotactic index of the polymer.

In a general embodiment, the present disclosure provides a filledcomposition made from and/or containing:

-   -   (A) a first polymer composition, and    -   (B) a biofiller composition.

In a general embodiment, the present disclosure provides a filledcomposition made from and/or containing:

-   -   (A) a first polymer composition made from and/or containing        -   (i) a heterophasic polypropylene copolymer and        -   (ii) a polypropylene blend, and    -   (B) a biofiller composition made from and/or containing a        cellulose-based biofiller.

In a general embodiment, the present disclosure provides a filledcomposition made from and/or containing:

-   -   (A) a first polymer composition made from and/or containing        -   (i) a first heterophasic polypropylene copolymer,        -   (ii) a polypropylene blend selected from the group            consisting of:            -   (a) a first polymer blend made from and/or containing                -   (1) a second heterophasic polypropylene copolymer                    and                -   (2) a third heterophasic polypropylene copolymer,            -   (b) a second polymer blend made from and/or containing                -   (1) the second heterophasic polypropylene copolymer                    and                -   (2) a first homopolymer polypropylene,            -   (c) a third polymer blend made from and/or containing                -   (1) a second homopolymer polypropylene and                -   (2) a third homopolymer polypropylene,    -   (B) a biofiller composition made from and/or containing a        cellulose-based biofiller.

In an embodiment, heterophasic polypropylene copolymers for use as thefirst heterophasic polypropylene copolymer have a melt flow rate in therange of about 10 grams per 10 minutes to about 40 grams per 10 minutes.The first heterophasic polypropylene copolymer can have a melt flow ratein the range of about 15 grams per 10 minutes to about 25 grams per 10minutes. In some embodiments, the first heterophasic polypropylenecopolymer will have a melt flow rate of 15, 16, 17, 18, 19, 20, 21, 22,23, 24, or 25 grams per 10 minutes.

In an embodiment, heterophasic polypropylene copolymers for use as thefirst heterophasic polypropylene copolymer can have a Percent XyleneSolubles in the range of about 10 weight percent to about 40 weightpercent weight percent, based on the total weight of the heterophasicpolypropylene copolymer. The first heterophasic polypropylene copolymercan have a Percent Xylene Solubles in the range of about 15 weightpercent to about 30 weight percent weight percent, based on the totalweight of the heterophasic polypropylene copolymer.

The heterophasic copolymer can be prepared by sequential polymerizationin at least two stages and in the presence of Ziegler-Natta catalystsupported on a magnesium halide in active form.

The polymerization process, which can be continuous or batch, is carriedout in liquid phase, in the presence or not of inert diluent, or in gasphase, or by mixed liquid-gas techniques.

The stereospecific polymerization catalysts comprise the product of thereaction between: 1) a solid component, containing a titanium compoundand an electron-donor compound (internal donor) supported on magnesiumdihalide; 2) an aluminum alkyl compound (cocatalyst); and, optionally,3) an electron-donor compound (external donor).

In an embodiment, the second heterophasic polypropylene copolymers foruse in making the polymer blend can have a melt flow rate in the rangeof about 50 grams per 10 minutes to about 200 grams per 10 minutes. Thesecond heterophasic polypropylene copolymer can have a melt flow rate inthe range of about 80 grams per 10 minutes to about 150 grams per 10minutes. In some embodiments, the melt flow rate will be in the range offrom about 100 grams per 10 minutes to about 120 grams per 10 minutes.

In an embodiment, the second heterophasic polypropylene copolymers foruse in making the polymer blend can have a Percent Xylene Solubles inthe range of about 5 weight percent to about 20 weight percent weightpercent, based on the total weight of the heterophasic polypropylenecopolymer. The second heterophasic polypropylene copolymer can have aPercent Xylene Solubles in the range of about 5 weight percent to about15 weight percent weight percent, based on the total weight of theheterophasic polypropylene copolymer. In some embodiments, the secondheterophasic polypropylene copolymer will have a Percent Xylene Solublesof 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 weight percent weightpercent, based on the total weight of the heterophasic polypropylenecopolymer.

In some embodiments, the third heterophasic polypropylene copolymers foruse in making the polymer blend can have a melt flow rate in the rangeof about 0.5 grams per 10 minutes to about 10 grams per 10 minutes. Thethird heterophasic polypropylene copolymer can have a melt flow rate inthe range of about 1 grams per 10 minutes to about 5 grams per 10minutes. In some embodiments, the third heterophasic polypropylenecopolymer will have a melt flow rate of 1, 2, 3, 4, or 5 grams per 10minutes.

In an embodiment, the third heterophasic polypropylene copolymers foruse in making the polymer blend can have a Percent Xylene Solubles inthe range of about 5 weight percent to about 20 weight percent, based onthe total weight of the heterophasic polypropylene copolymer. The thirdheterophasic polypropylene copolymer can have a Percent Xylene Solublesin the range of about 5 weight percent to about 15 weight percent weightpercent, based on the total weight of the heterophasic polypropylenecopolymer. In some embodiments, the third heterophasic polypropylenecopolymer will have a Percent Xylene Solubles of 5, 6, 7, 8, 9, 10, 11,12, 13, 14, or 15 weight percent weight percent, based on the totalweight of the heterophasic polypropylene copolymer.

Such heterophasic copolymers are commercially available as HIFAX™(LyondellBasell) and PROFAX™ (LyondellBasell) polypropylene.

In some embodiments, the first homopolymer polypropylene for use inmaking the polymer blend have a melt flow rate in the range of about1000 grams per 10 minutes to about 3000 grams per 10 minutes. The firsthomopolymer polypropylene can have a melt flow rate in the range ofabout 1500 grams per 10 minutes to about 2000 grams per 10 minutes.

In some embodiments, the second homopolymer polypropylene for use inmaking the polymer blend have a melt flow rate in the range of about 0.5grams per 10 minutes to about 30 grams per 10 minutes. The secondhomopolymer polypropylene can have a melt flow rate in the range ofabout 1 grams per 10 minutes to about 5 grams per 10 minutes. In someembodiments, the second homopolymer polypropylene will have a melt flowrate of 1, 2, 3, 4, or 5 grams per 10 minutes.

In some embodiments, the third homopolymer polypropylene for use inmaking the polymer blend have a melt flow rate in the range of about 50grams per 10 minutes to about 150 grams per 10 minutes. The thirdhomopolymer polypropylene can have a melt flow rate in the range ofabout 50 grams per 10 minutes to about 100 grams per 10 minutes. In someembodiments, the melt flow rate will be in the range of from about 60grams per 10 minutes to about 70 grams per 10 minutes.

Such homopolymer polypropylenes are commercially available as ADSTIF™(LyondellBasell), METOCENE™ (LyondellBasell), and PROFAX™(LyondellBasell) polymers.

The biofiller composition can be made from and/or contain acellulose-based biofiller. Examples of cellulose-based biofillersinclude wood-based biofillers.

The biofiller can be added as a neat filler or as part of a masterbatch.In some embodiments, the filled composition can have the biofillerpresent in an amount in the range from about 5 to about 50 weightpercent, based upon the total weight of the filled composition. In otherembodiments, the filled composition can have the biofiller present in anamount in the range from about 5 to about 40 weight percent, based uponthe total weight of the filled composition. In some other embodiments,the filled composition can have the biofiller present in an amount inthe range from about 10 to about 30 weight percent.

The masterbatch can be made from and/or contain the cellulose fiber anda virgin polymer. In some embodiments, the weight percent of cellulosefiber in a masterbatch can be in the range of about 10 weight percent toabout 90 weight percent, based on the total weight of the masterbatch.In other embodiments, the wood-based biofillers will have a weightpercent of cellulose fiber present in a weight percent from about 40 toabout 90. In yet other embodiments, the wood-based biofillers will havea weight percent of cellulose fiber present in a weight percent fromabout 50 to about 80.

In another embodiment, the biofiller composition is additionally madewith and/or contains an inorganic filler. Inorganic fillers includetalc.

In another embodiment, the filled composition additionally is made withand/or contains an additives composition having one or more additives.

Exemplary additives include colorants, odorants, deodorants,plasticizers, impact modifiers, nucleating agents, lubricants,surfactants, wetting agents, flame retardants, ultraviolet lightstabilizers, antioxidants, biocides, metal deactivating agents,thickening agents, heat stabilizers, defoaming agents, coupling agents,polymer alloy compatibilizing agent, blowing agents, emulsifiers,crosslinking agents, waxes, particulates, flow promoters, and othermaterials added to enhance processability or end-use properties of thepolymeric components. Such additives can be used in conventionalamounts. In some embodiments, the amounts do not exceed 10 weightpercent of the total composition.

In some embodiments, the filled composition is additionally made withand/or contains an elastomeric ethylene copolymer composition can bemade from and/or contains an elastomeric ethylene copolymer. Examples ofelastomeric ethylene copolymer include ethylene/alpha-olefin copolymerswith at least one C₃ to C₁₀ alpha-olefin comonomer, and optionally, apolyene comonomer. The alpha-olefin can also contain a cyclic structuresuch as cyclohexane or cyclopentane, resulting in an alpha-olefin suchas 3-cyclohexyl-1-propene (allyl-cyclohexane) and vinyl-cyclohexane. Theelastomeric ethylene copolymer can be an ethylene/alpha-olefincopolymers with (a) ethylene-derived units and (b) alpha-olefincomonomer units derived from at least one comonomer selected from thegroup consisting of C₃ to C₁₀ alpha-olefins. In some embodiments, theelastomeric ethylene copolymer is an ethylene/octene copolymer. In otherembodiments, the ethylene/octene copolymer has a melt index from about0.2 to about 6.0 grams per 10 minutes and a density from about 0.850 toabout 0.900 grams per cubic centimeter.

Exemplary elastomeric ethylene copolymers include, but are not limitedto, ethylene/propylene, ethylene/butene, ethylene/1-octene,ethylene/5-ethylidene-2-norbornene, ethylene/5-vinyl-2-norbornene,ethylene/-1,7-octadiene, ethylene/7-methyl-1,6-octadiene,ethylene/styrene, and ethylene/1,3,5-hexatriene. Exemplary elastomericethylene terpolymers include ethylene/propylene/1-octene,ethylene/butene/1-octene, ethylene/propylene/5-ethylidene-2-norbornene,ethylene/butene/5-ethylidene-2-norbornene, ethylene/butene/styrene,ethylene/1-octene/5-ethylidene-2-norbornene,ethylene/propylene/1,3-pentadiene,ethylene/propylene/7-methyl-1,6-octadiene,ethylene/butene/7-methyl-1,6-octadiene,ethylene/1-octene/1,3-pentadiene, andethylene/propylene/1,3,5-hexatriene. Exemplary elastomeric ethylenetetrapolymers include ethylene/propylene/1-octene/diene,ethylene/butene/1-octene/diene, and ethylene/propylene/mixed dienes.

Such elastomeric ethylene copolymers are commercially available asENGAGE™ (The Dow Chemical Company), EXACT™ (ExxonMobil ChemicalCompany), or TAFMER™ (Mitsui Chemical) polymers.

In another embodiment, the filled composition additionally is made withand/or contains a grafted polyolefin composition. The grafted polyolefincomposition is made from and/or containing a polypropylene polymergrafted with an unsaturated monomer.

In some embodiments, grafted polyolefins for use in making the graftedpolyolefin composition are prepared by reacting polyolefins withunsaturated monomers at elevated temperatures, with or without afree-radical initiator, to graft unsaturated monomer units onto thepolyolefin backbone. The grafting reaction can occur under an inert gas,such as nitrogen.

Polyolefins for making the grafted polyolefins can includepolypropylenes, ethylene-propylene copolymers, impact-modifiedpolypropylenes, and the like, and blends thereof

Unsaturated monomers can be ethylenically unsaturated carboxylic acidsand acid derivatives, particularly esters, anhydrides, acid salts, andthe like. Examples include acrylic acid, methacrylic acid, maleic acid,fumaric acid, itaconic acid, citraconic acid, maleic anhydride,tetrahydrophthalic anhydride, norborn-5-ene-2,3-dicarboxylic acidanhydride, nadic anhydride, himic anhydride, and the like, and mixturesthereof. Other unsaturated monomers are described in U.S. Pat. No.6,385,777 and U.S. Patent Application Publication No. 2007/0054142, theteachings of which are incorporated herein by reference.

The relative amounts of polyolefin and unsaturated monomer used willvary and depend on factors such as the nature of the polyolefin and theunsaturated monomer, the desired tie-layer properties, the reactionconditions, the available equipment, and other factors. In someembodiments, the unsaturated monomer is used in an amount within therange of about 0.1 to about 15 weight percent, based on the total weightof the grafted polyolefin. The unsaturated monomer can be in the rangeof from about 0.5 to about 6 weight percent. In some embodiments, therange can be from about 1 to about 3 weight percent.

Grafting of the unsaturated monomer(s) to the polyolefin can beaccomplished by heating a mixture of the unsaturated monomer(s) and thepolyolefin. The grafted polyolefin can be prepared by melt blending thepolyolefin with the unsaturated monomer in a shear-impartingextruder/reactor. Twin screw extruders such as those marketed byCoperion under the designations ZSK-53, ZSK-83, ZSK-90 and ZSK-92 areuseful for performing the grafting step. A free-radical initiator suchas an organic peroxide can be employed.

Grafting of the unsaturated monomer to the polyolefin is performed atelevated temperatures. Shear rates in the extruder can vary over a widerange.

The grafted polyolefin composition can be present in an amount fromabout 0.5 to about 5 weight percent, relative to the total weight of thefilled composition. In some embodiments, the grafted polyolefincomposition is present in an amount from about 1 to about 5 weightpercent. In other embodiments, the grafted polyolefin is present in 1,2, 3, 4, or 5 weight percent, relative to the total weight of the filledcomposition.

In another embodiment, heterophasic polypropylene copolymers for use asthe first heterophasic polypropylene copolymer have a melt flow rate inthe range of about 50 grams per 10 minutes to about 200 grams per 10minutes. The first heterophasic polypropylene copolymer can have a meltflow rate in the range of about 80 grams per 10 minutes to about 150grams per 10 minutes. In some embodiments, the melt flow rate will be inthe range of from about 100 grams per 10 minutes to about 120 grams per10 minutes.

In some embodiments, the present disclosure provides a filledcomposition having a melt flow rate (ASTM D1238) in the range of about 3grams per 10 minutes to about 20 grams per 10 minutes. In otherembodiments, the filled composition can have a melt flow rate in therange of about 5 to about 10 grams per 10 minutes. In some embodiments,the filled composition can have a melt flow rate of 5, 6, 7, 8, 9, or 10grams per 10 minutes.

In some embodiments, the present disclosure provides a filledcomposition having a density (ISO 1183) in the range of about 0.920grams per cubic centimeter to about 1.070 grams per cubic centimeter. Inother embodiments, the filled composition can have a density in therange of about 0.950 grams per cubic centimeter to about 1.000 grams percubic centimeter. In some embodiments, the filled composition can have adensity of 0.950, 0.960, 0.970, 0.980, 0.990, or 1.00 grams per cubiccentimeter.

In some embodiments, the present disclosure provides a filledcomposition having a tensile strength, 50 mm/min (ISO 527) in the rangeof about 20 MPa to about 40 MPa. In other embodiments, the filledcomposition can have a tensile strength in the range of about 25 toabout 35 MPa. In some embodiments, the filled composition can have atensile strength of 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, or 35 MPa.

In some embodiments, the present disclosure provides a filledcomposition having an elongation-at-break, 50 mm/min (ISO 527) in therange of about 3 percent to about 60 percent. In other embodiments, thefilled composition can have an elongation-at-break in the range of about5 percent to about 30 percent.

In some embodiments, the present disclosure provides a filledcomposition having a flexural modulus, 2 mm/min (ISO 178) in the rangeof about 1300 MPa to about 3000 MPa. In some embodiments, the filledcomposition can have a flexural modulus in the range of about 1500 toabout 2500 MPa.

In some embodiments, the present disclosure provides a filledcomposition having an Izod Impact at 23 degrees Celsius (ISO 180) in therange of about 2 kJ/m² to about 20 kJ/m². In other embodiments, thefilled composition can have an Izod Impact at 23 degrees Celsius in therange of about 3 to about 10 kJ/m².

In some embodiments, the present disclosure provides a filledcomposition having an Izod Impact at −10 degrees Celsius (ISO 180) inthe range of about 1 kJ/m² to about 10 kJ/m². In other embodiments, thefilled composition can have an Izod Impact at −10 degrees Celsius in therange of about 2 to about 7 kJ/m². In yet other embodiments, the filledcomposition can have an Izod Impact at −10 degrees Celsius of about 2,3, 4, 5, 6, or 7 kJ/m².

In some embodiments, the present disclosure provides a filledcomposition having an Izod Impact at −30 degrees Celsius (ISO 180) inthe range of about 1 kJ/m² to about 6 kJ/m². In other embodiments, thefilled composition can have an Izod Impact at −30 degrees Celsius in therange of about 2 to about 4 kJ/m².

In some embodiments, the present disclosure provides a filledcomposition having an HDT at 0.45 MPa (ISO 75) in the range of about 90degrees Celsius to about 150 degrees Celsius. In other embodiments, thefilled composition can have an HDT at 0.45 MPa in the range of about 100to about 140 degrees Celsius.

In some embodiments, the present disclosure provides a filledcomposition having a Rockwell Hardness (ASTM D785) on the R-Scale in therange of about 70 to about 100. In other embodiments, the filledcomposition can have a Rockwell Hardness on the R-Scale in the range ofabout 80 to about 100.

In a general embodiment, the present disclosure provides a filledcomposition made from and/or containing:

-   -   (A) from about 50 to about 95 weight percent of a first polymer        composition, relative to the total weight of the filled        composition, made from and/or containing        -   (i) from about 5 to about 35 weight percent of a first            heterophasic polypropylene copolymer, relative to the total            weight of the filled composition,        -   (ii) from about 15 to about 70 weight percent of a            polypropylene blend, relative to the total weight of the            filled composition, and    -   (B) from about 5 to about 50 weight percent of a biofiller        composition made from and/or containing a cellulose-based        biofiller, relative to the total weight of the filled        composition.

In some embodiments, the first heterophasic polypropylene copolymer ispresent in an amount from about 10 to about 30 weight percent, relativeto the total weight of the filled composition. In other embodiments, thefirst heterophasic polypropylene copolymer is present in an amount fromabout 15 to about 25 weight percent. In other embodiments, the firstheterophasic polypropylene copolymer is present in 15, 16, 17, 18, 19,20, 21, 22, 23, 24, or 25 weight percent, relative to the total weightof the filled composition.

In some embodiments, the polypropylene blend is present in an amountfrom about 20 to about 60 weight percent, relative to the total weightof the filled composition. In other embodiments, the polypropylene blendis present in an amount from about 20 to about 50 weight percent. Inother embodiments, the polypropylene blend is present in an amount fromabout 20 to about 45 weight percent.

In some embodiments, the biofiller composition is present in an amountfrom about 10 to about 30 weight percent, relative to the total weightof the filled composition.

In some embodiments, the filled composition is additionally made withand/or contains an elastomeric ethylene copolymer composition, which ispresent in an amount from about 5 to about 20 weight percent, relativeto the total weight of the filled composition. In other embodiments, theelastomeric ethylene copolymer composition is present in an amount fromabout 10 to about 15 weight percent. In some embodiments, theelastomeric ethylene copolymer composition is present in 10, 11, 12, 13,14, or 15 weight percent, relative to the total weight of the filledcomposition.

In some embodiments, the filled composition is additionally made withand/or contains a grafted polyolefin composition, which is present in anamount from about 0.5 to about 5 weight percent, relative to the totalweight of the filled composition. In some embodiments, the graftedpolyolefin composition is present in an amount from about 1 to about 5weight percent. In other embodiments, the grafted polyolefin is presentin 1, 2, 3, 4, or 5 weight percent, relative to the total weight of thefilled composition.

In a general embodiment, the present disclosure provides an automotivecomponent made from and/or containing:

-   -   (A) a first polymer composition made from and/or containing        -   (i) a first heterophasic polypropylene copolymer,        -   (ii) a polypropylene blend selected from the group            consisting of:            -   (a) a first polymer blend made from and/or containing                -   (1) a second heterophasic polypropylene copolymer                    and                -   (2) a third heterophasic polypropylene copolymer,            -   (b) a second polymer blend made from and/or containing                -   (1) the second heterophasic polypropylene copolymer                    and                -   (2) a first homopolymer polypropylene,            -   (c) a third polymer blend made from and/or containing                -   (1) a second homopolymer polypropylene and                -   (2) a third homopolymer polypropylene, and    -   (B) a biofiller composition made from and/or containing a        cellulose-based biofiller.

In some embodiments, the automotive component is additionally made withand/or contains an elastomeric ethylene copolymer composition can bemade from and/or contains an elastomeric ethylene copolymer.

In some embodiments, the automotive component additionally is made withand/or contains a grafted polyolefin composition. The grafted polyolefincomposition is made from and/or containing a polypropylene polymergrafted with an unsaturated monomer.

Examples

The following examples are included to demonstrate embodiments of theinvention. It should be appreciated by those of skill in the art thatthe techniques disclosed in the examples which follow representtechniques discovered by the inventor to function well in the practiceof the invention, and thus can be considered to constitute exemplarymodes for its practice. However, those of skill in the art should, inlight of the present disclosure, appreciate that many changes can bemade in the specific embodiments which are disclosed and still obtain alike or similar result without departing from the spirit and scope ofthe invention.

Heterophasic Polypropylene Copolymers: HeCo-1 polypropylene (Melt FlowRate: 4.0 grams per 10 minutes; Density of 0.900 grams per cubiccentimeter; Percent Xylenes Soluble (weight percent): 11.5), HeCo-2polypropylene (Melt Flow Rate: 18 grams per 10 minutes; Density of 0.900grams per cubic centimeter; Percent Xylenes Soluble (weight percent):23.2; M_(w)/M_(n): 7.01; M_(n): 3.36E+04; M_(w): 2.35E+05; M_(z):7.61E+05; and M_(z+1): 1.46E+06), HeCo-3 polypropylene (Melt Flow Rate:100 grams per 10 minutes; Density of 0.900 grams per cubic centimeter;Percent Xylenes Soluble (weight percent): 11.7; M_(w)/M_(n): 5.49;M_(n): 2.99E+04; M_(w): 1.64E+05; M_(z): 6.34E+05; and M_(z+1):1.48E+06), and HeCo-4 polypropylene (Melt Flow Rate: 120 grams per 10minutes) polypropylene.

Polypropylene Homopolymers: Homo-1 polypropylene (Melt Flow Rate: 2.3grams per 10 minutes; Density of 0.90 grams per cubic centimeter;M_(w)/M_(n): 7.0; M_(n): 5.8E+04; M_(w): 4.1E+05; M_(z): 1.2E+06; andM_(z+1): 2.3+06), Homo-2 polypropylene (Melt Flow Rate: 65 grams per 10minutes; Density of 0.90 grams per cubic centimeter; M_(w)/M_(n): 6.1;M_(n): 2.9E+04; M_(w): 1.8E+05; M_(z): 5.9E+05; and M_(z+1): 1.1E+06),and Homo-3 polypropylene (Melt Flow Rate: 1800 grams per 10 minutes;Density of 0.91 grams per cubic centimeter; M_(w)/M_(n): 3.2; M_(n):1.56E+04; M_(w): 5.0E+04; M_(z): 1.08E+05; and M_(z+1): 1.68E+05).

Elastomeric Ethylene Copolymer: ethylene/octene copolymer (Melt Index:1.0 grams per 10 minutes; Density of 0.870 grams per cubic centimeter).

Grafted Polyolefin: maleic anhydride grafted polypropylene (Melt FlowRate: 100 grams per 10 minutes: Density of 0.90 grams per cubiccentimeter).

Cellulose-based Biofiller Masterbatch: cellulose-based biofillermasterbatch (fiber content of about 70 weight percent, based on thetotal weight of the biofiller; about 25 weight percent virginpolypropylene; a specific gravity of 1.27; and a fiber length of about 1mm).

Additives: Carbon black masterbatch (50% carbon black masterbatch inpolyethylene); antioxidant processing stabilizer; Magnesium stearatelubricant; Sodium benzoate nucleating agent; and slip agent.

TABLE 1 Component*/Test** Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 HeCo-1polypropylene 3.25 HeCo-2 polypropylene 25.00 20.00 20.00 20.00 HeCo-3polypropylene 35.00 30.00 10.00 HeCo-4 polypropylene 15.00 Homo-1polypropylene 7.00 8.00 Homo-2 polypropylene 39.40 33.40 Homo-3polypropylene 6.25 13.65 Ethylene/octene copolymer 15.00 13.00 15.0010.00 Maleic anhydride grafted polypropylene 2.00 2.00 Cellulose-basedbiofiller masterbatch 21.00 30.00 40.60 30.00 30.00 Antioxidantprocessing stabilizer 0.20 0.20 0.20 0.20 0.20 Sodium benzoate 0.15 0.150.15 Slip agent 0.40 0.40 0.40 Carbon black masterbatch 1.00 1.00Magnesium stearate 0.40 0.40 Total 100.00 100.00 100.00 100.00 100.00Melt Flow Rate (ASTM D1238)- 5.4 5.3 5.8 7.4 10.4 g/10 min Density (ISO1183)-g/cc 0.96 0.99 1.00 0.99 0.99 Tensile Strength, 50 mm/min 24.128.6 31.6 35.0 31.8 (ISO 527)-MPa Elongation-at-Break, 50 mm/min 18 1010 4 7 (ISO 527)-% Flexural Modulus, 2 mm/min 1,610 1,850 2,030 2,4162,093 (ISO 178)-MPa Izod Impact at 23 degrees Celsius 10.1 6.9 7.1 2.53.0 (ISO 180)-kJ/m² Izod Impact @ −10 degrees Celsius 2.0 2.5 (ISO180)-kJ/m² Izod Impact @ −30 degrees Celsius 3.7 3.2 3.3 (ISO 180)-kJ/m²HDT @ 0.45 NiPa (ISO 75)- 107 119 129 140 137 degrees Celsius RockwellHardness (ASTM D785)- 97 90 R-Scale *All weight percentages are basedupon the total weight of the final composition. **The ISO data forExample Nos. 4 and 5 are projected based upon ASTM data.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of the ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

What is claimed is:
 1. A filled composition comprising: (A) a firstpolymer composition comprising: (i) a first heterophasic polypropylenecopolymer; and (ii) a polypropylene blend selected from the groupconsisting of: (a) a first polymer blend comprising: (1) a secondheterophasic polypropylene copolymer; and (2) a third heterophasicpolypropylene copolymer; (b) a second polymer blend comprising: (1) thesecond heterophasic polypropylene copolymer; and (2) a first homopolymerpolypropylene; (c) a third polymer blend comprising: (1) a secondhomopolymer polypropylene; and (2) a third homopolymer polypropylene;and (B) a biofiller composition comprising a cellulose-based biofiller.2. The filled composition of claim 1, wherein the first heterophasicpolypropylene copolymer has a melt flow rate in the range of about 10grams per 10 minutes to about 40 grams per 10 minutes.
 3. The filledcomposition of claim 2, wherein the polypropylene blend is the firstpolymer blend; and (A) the second heterophasic polypropylene copolymerhas a melt flow rate in the range of about 50 grams per 10 minutes toabout 200 grams per 10 minutes; and (B) the third heterophasicpolypropylene copolymer has a melt flow rate in the range of about 0.5grams per 10 minutes to about 10 grams per 10 minutes.
 4. The filledcomposition of claim 2, wherein the polypropylene blend is the secondpolymer blend; and (A) the second heterophasic polypropylene copolymerhas a melt flow rate in the range of about 50 grams per 10 minutes toabout 200 grams per 10 minutes; and (B) the first homopolymerpolypropylene having a melt flow rate in the range of about 1000 gramsper 10 minutes to about 3000 grams per 10 minutes.
 5. The filledcomposition of claim 2, wherein the polypropylene blend is the thirdpolymer blend; and (A) the second homopolymer polypropylene has a meltflow rate in the range of about 0.5 grams per 10 minutes to about 30grams per 10 minutes; and (B) the third homopolymer polypropylene has amelt flow rate in the range of about 50 grams per 10 minutes to about150 grams per 10 minutes.
 6. The filled composition of claim 1, whereinthe biofiller composition further comprises: an inorganic filler.
 7. Thefilled composition of claim 1, further comprising: an additivescomposition having one or more additives.
 8. The filled composition ofclaim 1, further comprising: an elastomeric ethylene copolymercomposition comprising an elastomeric ethylene copolymer.
 9. The filledcomposition of claim 1, further comprising: a grafted polyolefincomposition comprising a polypropylene polymer grafted with anunsaturated monomer.
 10. The filled composition of claim 1, wherein (A)the first heterophasic polypropylene copolymer has a melt flow rate inthe range of about 50 grams per 10 minutes to about 200 grams per 10minutes; and (B) the polypropylene blend is the third polymer blend,wherein (i) the second homopolymer polypropylene has a melt flow rate inthe range of about 0.5 grams per 10 minutes to about 30 grams per 10minutes; and (ii) the third homopolymer polypropylene has a melt flowrate in the range of about 50 grams per 10 minutes to about 150 gramsper 10 minutes.
 11. The filled composition of claim 1, having a densityas measured by ISO 1183 in the range of about 0.920 grams per cubiccentimeter to about 1.070 grams per cubic centimeter.
 12. The filledcomposition of claim 1, having a flexural modulus, 2 mm/min as measuredby ISO 178 in the range of about 1300 MPa to about 3000 MPa.
 13. Thefilled composition of claim 1, having an Izod Impact at 23 degreesCelsius as measured by ISO 180 in the range of about 2 kJ/m² to about 20kJ/m².
 14. A filled composition comprising: (A) from about 50 to about95 weight percent of a first polymer composition, relative to the totalweight of the filled composition, comprising: (i) from about 5 to about35 weight percent of a first heterophasic polypropylene copolymer,relative to the total weight of the filled composition; (ii) from about15 to about 70 weight percent of a polypropylene blend, relative to thetotal weight of the filled composition, selected from the groupconsisting of: (a) a first polymer blend comprising: (1) a secondheterophasic polypropylene copolymer; and (2) a third heterophasicpolypropylene copolymer; (b) a second polymer blend comprising: (1) thesecond heterophasic polypropylene copolymer; and (2) a first homopolymerpolypropylene; (c) a third polymer blend comprising: (1) a secondhomopolymer polypropylene; and (2) a third homopolymer polypropylene;and (B) from about 5 to about 50 weight percent of a biofillercomposition, relative to the total weight of the filled composition,comprising a cellulose-based biofiller.
 15. The filled composition ofclaim 14, further comprising: from about 5 to about 20 weight percent ofan elastomeric ethylene copolymer composition, relative to the totalweight of the filled composition, comprising an elastomeric ethylenecopolymer.
 16. The filled composition of claim 14, further comprising:from about 0.5 to about 5 weight percent of a grafted polyolefincomposition, relative to the total weight of the filled composition,comprising a polypropylene polymer grafted with an unsaturated monomer.17. The filled composition of claim 14, having a density as measured byISO 1183 in the range of about 0.920 grams per cubic centimeter to about1.070 grams per cubic centimeter.
 18. The filled composition of claim14, having a flexural modulus, 2 mm/min as measured by ISO 178 in therange of about 1300 MPa to about 3000 MPa.
 19. The filled composition ofclaim 14, having an Izod Impact at 23 degrees Celsius as measured by ISO180 in the range of about 2 kJ/m² to about 20 kJ/m².
 20. An automotivecomponent comprising: (A) a first polymer composition comprising: (i) afirst heterophasic polypropylene copolymer; and (ii) a polypropyleneblend selected from the group consisting of: (a) a first polymer blendcomprising: (1) a second heterophasic polypropylene copolymer; and (2) athird heterophasic polypropylene copolymer; (b) a second polymer blendcomprising: (1) the second heterophasic polypropylene copolymer; and (2)a first homopolymer polypropylene; (c) a third polymer blend comprising:(1) a second homopolymer polypropylene; and (2) a third homopolymerpolypropylene; and (B) a biofiller composition comprising acellulose-based biofiller.